Feeding system for electro-chemically polishing contact tips

Abstract

Electro-chemical polishing of fine wire contacts is facilitated by welding the wire contacts to a mounting element on a continuous, flexible, metal strip. The assembled contact strip is wound on a spool and transported to the electro-chemical polishing site where the contact strip is drawn into the polishing site at a constant rate under the control of a microprocessor. The progress of the assembled contact strip is monitored by metering rollers and pulse generators that inform the microprocessor of the drive speed of the assembled contact strip. The controller then provides signals to control the take-up and supply spools to ensure that a proper tip polishing operation is carried out.

What is claimed is:  
     
       1. A system for providing thin wire contacts to an electro-chemical polishing operation, the system comprising: 
       a flexible metal strip having a plurality of detachable metal mounting elements formed along a length of said strip;  
       a plurality of thin wire contacts arranged in a plurality of groups, one or more of said groups being attached by welding to each of said plurality of metal mounting element formed along said flexible metal strip;  
       a spool having wound thereon said flexible metal strip having said plurality of groups of thin wire contacts separably attached by welding to said plurality of metal mounting elements; and  
       means for uniformly moving said flexible metal strip having said plurality of groups of thin wire contacts separably attached by welding to said plurality of metal mounting elements from said spool into and through an electro-chemical polishing operation site, whereat tips of said plurality of tin wire contacts are polished.  
     
     
       2. The system for providing thin wire contacts to an electro-chemical polishing operation according to  claim 1 , wherein said spool forms a supply spool and further comprising a take-up spool for taking up said flexible metal strip having said plurality of thin wire contacts attached thereto following the electro-chemical polishing operation. 
     
     
       3. The system for providing thin wire contacts to an electro-chemical polishing operation according to  claim 2 , wherein said means for uniformly moving comprises: 
       a controller;  
       a drive motor for driving said take-up spool under control of said controller; and  
       a metering roller for detecting a drive rate of said flexible metal strip having said plurality of thin wire contacts separably attached thereto for providing a pulsed signal to said controller indicating said drive rate.  
     
     
       4. The system for providing thin wire contacts to an electro-chemical polishing operation according to  claim 3 , further comprising 
       means for applying a tension to said flexible metal strip having said plurality of thin wire contacts separably attached thereto while moving into and through said electro-chemical polishing operation site.  
     
     
       5. The system for providing thin wire contacts to an electro-chemical polishing operation according to  claim 1 , wherein said plurality of thin wire contacts in each of said groups are attached to said flexible metal strip in side-by-side arrangement and in physical contact with each other. 
     
     
       6. The system for providing thin wire contacts to an electo-chemical polishing operation according to  claim 1 , wherein said plurality of thin wire contacts in each of said groups are attached to said flexible metal strip in mutually spaced-apart relationship. 
     
     
       7. The system for providing thin wire contacts to an electro-chemical polishing operation according to  claim 1 , wherein free ends of said plurality of thin wire contacts are bent at a predetermined angle. 
     
     
       8. The system for providing thin wire contacts to an electro-chemical polishing operation according to  claim 1 , wherein free ends of said plurality of thin wire contacts are straight. 
     
     
       9. A system for providing thin wire contacts to an electro-chemical polishing site for tip polishing, the system comprising: 
       a flexible metal strip having a plurality of detachable metal mounting elements formed at regular intervals along a length of said strip;  
       a plurality of thin spring wires arranged in a plurality of groups, at least one of said groups being attached by welding to each of said plurality of detachable metal mounting elements formed on said flexible metal strip;  
       a supply spool having wound thereon said flexible metal strip having said plurality of groups of thin spring wires attached to said plurality of detachable metal mounting elements;  
       means for uniformly moving said flexible metal strip having said plurality of groups of thin spring wires attached to said plurality of detachable metal mounting elements from said spool into and through an electro-chemical tip polishing operation site, whereat tips of said plurality of thin spring wires ate polished; and  
       a take-up spool for taking up said flexible metal strip having said plurality of groups of thin spring wires attached to said plurality detachable metal mounting elements following the electro-chemical tip polishing operation.  
     
     
       10. The system for providing thin wire contacts to an electro-chemical polishing site for tip polishing according to  claim 9 , therein said means for uniformly moving comprises: 
       a system controller;  
       an input device connected to said controller for providing commands to said system controller upon operation by a user of the system;  
       a drive motor for driving said take-up spool under control of said system controller; and  
       a metering roller for detecting a drive rate of said flexible metal strip having said plurality of thin spring wires attached thereto for providing a pulsed signal to said system controller indicating said drive rate.  
     
     
       11. The system for providing thin wire contacts to an electro-chemical polishing site for tip polishing according to  claim 10 , further comprising 
       means for applying a tension to said flexible metal strip having said plurality of thin spring wires attached thereto while moving into and through said electro-chemical tip polishing operation site.  
     
     
       12. The system for providing thin wire contacts to an electro-chemical polishing site for tip polishing according to  claim 9 , wherein said plurality of thin wire contacts in each group are attached to said flexible metal strip in side-by-side arrangement and in physical contact with each other. 
     
     
       13. The system for providing thin wire contacts to an electro-chemical site for tip polishing according to  claim 9 , wherein said plurality of thin wire contacts in each group are attached to said flexible metal strip in a mutually spaced-apart relationship. 
     
     
       14. The system for providing thin wire contacts to an electro-chemical site for tip polishing according to  claim 9 , wherein free ends of said plurality of thin wire contacts are bent at a predetermined angle. 
     
     
       15. The system for providing thin wire contacts to an electro-chemical polishing site for tip polishing according to  claim 9 , wherein free ends of said plurality of thin wire contacts are straight. 
     
     
       16. A system for providing thin wire contacts to an electro-chemical polishing operation, the system comprising: 
       a straight strip formed of flexible metal having a plurality of detachable metal mounting elements arranged at even intervals along a length thereof;  
       a plurality of thin wire contacts arranged in a plurality of groups, one or more of said groups being attached by welding to each of said plurality of detachable metal mounting elements formed along said straight strip formed of flexible metal;  
       input means for moving said straight strip formed of flexible metal having said plurality of groups of thin wire contacts attached by welding to said plurality of detachable metal mounting elements into an electro-chemical polishing operation, whereat tips of said plurality of thin wire contacts are polished; and  
       output means for moving said straight strip formed of flexible metal having said plurality of groups of thin wire contacts attached to said detachable metal mounting elements out of the electro-chemical polishing operation site.  
     
     
       17. The system for providing thin wire contacts to an electro-chemical polishing operation according to  claim 16 , wherein said input means for moving comprises: 
       a drive roller;  
       an idler roller in contact with said drive roller; and  
       a drive motor for rotating said drive roller.  
     
     
       18. The system for providing thin wire contacts to an electro-chemical polishing operation according to  claim 17 , wherein said plurality of thin wire contacts in each of said groups are attached to said straight strip in side-by-side arrangement and in physical contact with each other. 
     
     
       19. The system for providing thin wire contacts to an elecro-chemical polishing operation according to  claim 17 , wherein said plurality of thin wire contacts in each of said groups are attached to said straight strip in mutually spaced-apart relationship. 
     
     
       20. The system for providing thin wire contacts to an electo-chemical polishing operation according to  claim 17 , wherein free ends of said plurality of thin wire contacts are bent at a predetermined angle. 
     
     
       21. The system for providing thin wire contacts to an electro-chemical polishing operation according to  claim 17 , wherein free ends of said plurality of thin wire contacts are straight.